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SECTION TITLE


ADDITIVE MANUFACTURING


mainly produced by CNC machining with further assembling of up to 27 parts. Te weight of these assembled parts could be up to 295g, resulting in slower reaction times and movement speeds. In addition, the assembled parts increased the potential for damage during impacts.


THE AM SOLUTION In early 2019, the SCUT team began to adopt Autodesk software and Farsoon AM technology to improve the design and manufacturing process. Te additive technology offers unprecedented freedom in flexibility of the geometry of design that suits best for the application. Tanks to generative design, a key


feature in Autodesk Fusion 360, the students are able to apply a variety of working conditions such as the extreme impact loads during competition to the part. Tey can then define the output options such as desired weight limit (lightweight target), engineering materials (including resin, nylon, aluminium), safety factor (up to eight) and potential processing method (CNC, milling, additive). Tis ensures the best performance of the part during the contest. All the options generated have been further explored and tested by the students so they could choose the optimal design for final manufacturing. Tree designs were chosen with


different materials and processing methods for assembly and field validation: resin (stereolithography); nylon (plastic laser sintering); and aluminium (metal laser melting). Te resin and nylon parts broke in the field impact, while the AlSi10Mg aluminium stabiliser mount produced by Farsoon FS271M metal laser melting technology stands out with its qualified strength, durability and performance.


Autodesk Fusion 360: explore and comparison of the generated options


Tis combination of generative design and AM completely overturns the concept of a traditional design process. It creates the optimal design in a very short time without the limitations of traditional processing and materials options.


IMPRESSIVE RESULTS Te optimised additive manufacturing stabiliser mount achieved a final weight of 170g – a 42% weight reduction compared to the original CNC process. Te lighter weight means a faster response to signals and improved mobility in the field. Simultaneously, by combining 27 parts to only one single part, it reduces the material waste while enhancing the strength by adding support, therefore reducing the mass of the robot while ensuring structural integrity. Tis new workflow also helps accelerate design iteration from the development process to manufacturing. Te traditional design by engineer is limited by his own experience, while generative design employs cloud computing to help generate and iterate the optimal result. Compared to traditional manufacturing, additive


SCUT robot with additive manufactured stabiliser during the competition


technology can build two sets of stabilisers in only two days. Te whole workflow is simplified with improved efficiency and it also it offers the best solutions for application. Faster design iteration helps the SCUT team to work more efficiently while reducing the cost of material and manufacturing. Tis year, the SCUT team achieved considerable cost reduction to research and development. For example, the mechanical team’s entire iterative cost was reduced by 80%, which would not have been possible before. With the help of innovative additive technology, the SCUT team entered the RoboMaster (South-China area) contest on May 23, 2019. Te optimised design and improved performance of the stabiliser mount enabled the SCUT team to win the championship again, despite some intense competition.


Original design and generative design by Autodesk Fusion 360 22 www.engineerlive.com


Chenlu Fang is with Farsoon Technologies. www.farsoon.com


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